ISOLATED DC-DC CONVERTER

Abstract

The invention describes a highly efficient, isolated DC-DC converter for switched-mode power supplies and energy conversion systems, usable in a wide input voltage range of 9-36ΩV or 18-72ΩV and / or for low output levels such as 5V / 4A, as well as adaptable to higher power applications such as 12V / 8.33A, while maintaining the same active clamp forward structure.

Description

1 Specifications ISOLATED DC-DC CONVERTER Technical Area The invention relates to power electronics. The invention is particularly suitable for high-performance switched-mode power supplies and energy conversion systems. It relates to efficient DC-DC converters. State of the Art Today, the classic 10-inch converter is still widely used in isolated DC-DC converter applications. Forward topologies are used. These structures offer advantages in terms of low complexity and cost. However, it offers several advantages, particularly a wide input voltage range, high efficiency, and low electromagnetic emissions. fully meets modern system requirements such as electromagnetic interference (EMI) and long-term reliability. He / She is unable to answer. Here are some of the main shortcomings encountered in classic forward converters today. These are: - Hard switching: Main switching elements (MOSFETs) It switches under high voltage, which results in high transient switching. It causes losses, electromagnetic radiation, and heating. 20 - Transformer magnetic reset problems: The reset circuit usually involves passive components. (snubber, RCD, etc.) are used. This can disrupt the magnetic balance of the transformer and This can lead to nucleus saturation over time. - Duty cycle limitations: Duty cycle limitations for safe operation in classic forward topologies. The cycle is usually limited to 50%. This provides sufficient output under low VIN conditions. This may lead to it not being obtained. - There is no energy recovery: The energy consumed in snubber circuits is generally... It is converted into heat and cannot be recovered. This negatively affects productivity. - Poor thermal load dissipation: Inadequate heat dissipation and low thermal load in compact designs. A lossy structure cannot be obtained. 30 - Most importantly, the products on the market are quite large and have excessive height from the ground. Also today, in the field of industrial power systems; automation panels, PLCs In areas such as power supply systems and motor drives, both low and high power DC- 2 DC conversions are needed. In communication infrastructures (telecommunications), Telecommunication systems typically operate with constant DC voltages such as -48V, 12V, and 5V. Again, the power used in the field of defense and aerospace electronics in current technology Features such as compact structure, high reliability and wide temperature / wide inlet range in their sources 5 These features are of critical importance in the field of renewable energy and energy storage systems. Variable input is used in applications such as solar panel regulators and battery charging systems. It is necessary to convert their voltages into stable and regulated outputs. Again, in the previous technique, in the field of medical and precision electronic systems; 10 for these devices The required low ripple and constant voltage sources are usually provided with special power modules. It is provided. All these limitations lead to efficiency loss and overheating, even in low-power systems. This leads to electromagnetic interference, increased size, and low reliability. Especially 15 In systems that need to operate over a wide input voltage range and supply sensitive loads. These problems are becoming even more pronounced. Also included in the current technology is US2022200454 (A1), “Large Capacity Two-Way With the invention titled "Isolated DC-DC Converter and Its Control Method", a large bidirectional 20 to meet the latest requirements for high-capacity isolated LDC (DC-DC converter) A new LDC has been provided. The current description describes two LDCs with different power circuit topologies. To enable both buck and boost modes of the converter, use parallel. It provides a new bidirectional isolated LDC that functions as such. The two converters implemented are fully functional. a phase-shifted full-bridge converter with bridge synchronous correction and a 25 active clamp converter It is an advanced converter. According to the current invention, it is both a full-bridge synchronous rectifier. both the implemented phase-shifted full-bridge converter and the active-clamped forward converter It is possible to obtain the advantages of the converter. Thus, the output voltage and current. to minimize fluctuations, thus reducing the electromagnetic radiation produced while a product is operating. It is possible to improve the quality of LDC output power while minimizing ripple. 30 Again, US2024072641 (A1), “Including Current Detection Peak Control Mode Control The invention entitled "Active Clamp DC / DC Converter" describes an isolated DC / DC converter. a primary stage, a transformer circuit, a secondary stage, an active clamp, a 3 It includes a primary current sensing node and a secondary current sensing node. Primary The step converts the source DC voltage to high-frequency alternating current (AC) voltage. It includes a primary switching inverter configured for. The transformer circuit, high frequency AC voltage adjusts the AC voltage level and a set AC voltage It provides the output. The secondary stage converts the regulated AC voltage into a secondary voltage. 5 It includes a secondary switching converter and an active clamp, providing an output DC voltage. It is configured to clamp the secondary voltage in order to provide the primary current. The sensing node is included in the primary stage and is a source with a primary current level. It transmits the current, and the second current sensing node is included in the secondary stage, and the second current A clamp with a level 10 transmits current. The purpose of the invention The invention aims to eliminate the disadvantages inherent in the prior art. One objective is to technically improve the existing active clamp forward converter topology. It offers an improved and application-optimized version. Invention 15 The subject matter is a compact, high-efficiency, stable-operating system operating over a wide input voltage range. It stands out with its architecture that can adapt to different power levels. Another aim of the invention is to provide a wide input voltage range and high efficiency. It is an ideal solution to be preferred in applications that have specific requirements. 20 Another aim of the invention is to ensure the safety and reliability of these systems with stable and precise output voltages. Its purpose is to ensure stable operation. Another objective of the invention is active clamping, synchronous rectification and multi-25 Its layered PCB compatibility makes it suitable for such demanding conditions. Another aim of the invention is a wide input voltage range (e.g., 9–36 V or 18–72 V). Thanks to this invention, it can be used directly in solar and battery-based systems. That is. 30 Another aim of the invention is to provide high accuracy, low noise and compact design features. It also requires adaptation to these areas. 4 Another purpose of the invention is to assist in the field of electric vehicles and intelligent transportation systems. power units (auxiliary power units), display systems, battery management systems It is a usable, insulated, and safe converter solution. Another objective of the invention is the active clamp forward topology, synchronous rectifier structure, 5 Advanced control layers such as hiccup protection, soft-start, UVLO, and feedback. Thanks to this, it provides a solution for all DC-DC conversion needs requiring high performance. It is to present. Another objective of the invention is High Efficiency; the system has an active clamp structure of 10. using zero voltage switching (ZVS) in switching elements This has been achieved, energy recovery has been provided in the damping elements, and transmission has been improved. Losses have been minimized. Additionally, it features a synchronous rectification structure and an external gate drive. With integrated circuits, lower losses have been achieved, especially at low output voltages. Another objective of the invention is compact structure and high-density PCB design; Our PCBs are designed with a special 16-layer stack-up structure, which allows them to both It offers superior stability in terms of both EMI / EMC performance and thermal management. This design allows for the transmission of more power in a smaller volume, ensuring a more holistic system. Reliability is increased. Additionally, the total height and overall dimensions of the card are 20. It offers a more compact structure compared to its counterparts. Another objective of the invention is to operate without a load (no minimum load); the circuit, It has been tested to ensure stable operation without minimum load requirements. This In this way, the system's output voltage is protected without degradation, even during sudden changes in load. 25 Another purpose of the invention is soft-start; soft-start function. In this way, the output voltage is gradually increased, avoiding sudden voltage surges on both the load and the power components. It protects against current stress. Another objective of the invention is to provide input / output voltage flexibility; the system's output voltage can be ±10%. It has an adjustable structure in terms of ratio. In addition, the product family is suitable for different I / O voltage levels. It is designed to be easily customized. Another aim of the invention is high reliability and long service life; the product, therefore, is highly... designed with components suitable for long-term operation at high temperatures, extreme temperatures Integrated protection is provided. High reliability backed by a manufacturer's warranty. that is the goal. Another aim of the invention is to provide advanced protection functions; UVLO (Under- Voltage lockout), over-temperature protection, and input protection circuit (with current transformer), etc. Protective layers are present. This ensures both circuit safety and the safety of connected loads. protection is ensured. Another objective of the invention is to provide high mechanical and environmental resistance; heat absorber (heat- Thanks to its sink-molded structure and reinforced pin-out arrangement, the product is suitable for harsh environments. It is resistant to these conditions. Another aim of the invention is design flexibility; the same control infrastructure and circuit 15 Its architecture allows for more than 30 different output voltages, current ratings, and power levels. Different models have been developed, and this structure has been modularized. Another aim of the invention is rapid delivery – in terms of suitability for production; the design is both low-cost. High 20, optimized for both small-scale prototyping and mass production processes. Feasibility has been taken into consideration. In an alternative configuration of the invention, both desktop and embedded systems are available. Various pin-out layouts and packaging options can be implemented for different uses. In another alternative configuration, the invention could be used in automotive electronics or the defense industry. solutions, communication infrastructure, industrial automation, medical devices, energy applicable to all systems used as monitoring systems and power modules. It offers a flexible power converter infrastructure. The invention in question is limited only to the specific output values ​​in the current specification. not, but for different voltage and current configurations based on the same architectural structure. It can be designed in a scalable manner. The design includes output voltage, output current, power level, and It has a customizable infrastructure in terms of card sizes. 6 Explanation of the Figures Figure 1 shows the primary side structure of the converter that is the subject of the invention. Figure 2 shows the secondary side structure of the converter that is the subject of the invention, 5 Figure 3 shows the control unit of the converter that is the subject of this invention. Figure 4 shows the gate drives of the converter that is the subject of this invention. Figure 5 shows the ripple and noise full load view of the converter that is the subject of this invention. Figure 6 shows the transient response of the converter, which is the subject of the invention, with a 25% load step change. It is the appearance, 10 Figure 7 shows one of the sample 20-watt pinouts of the converter that is the subject of the invention. It is the appearance, Figure 8 shows the external dimension view of the converter, which is the subject of the invention. Explanation of Reference Numbers Reference Number Reference Name 1. Primary party structure 11 Winch entrance 12 Main power MOSFETs 13 Clamp MOSFET 14 Transformer (T1) 2 Secondary Party 21 Synchronous MOSFETs 22 Output LC Filter 23 Vout Terminals 3 Control units 31 PWM Controllers 32 Feedback Inputs 4-Gate drives 41 Gate drive (second side) 7 Detailed Description of Find The invention relates to switched-mode power supplies and energy conversion systems; 9–36 V or 18– For a wide input voltage range of 72V and / or low output levels such as 5V / 4A. As it can be used, the same active power supply is also available for higher power applications such as 12V / 8.33A. Switched-mode power supplies that can be adapted while maintaining a clamp forward structure, energy 5 It is a high-efficiency isolated DC-DC converter for conversion systems. Figure 1 shows the primary side structure (1) of the converter that is the subject of the invention. The Primary Party Structure (1) includes the following: - Vin Input (11): Accepts a wide range of DC input voltage (e.g. 9–36V). 10 It is supported by an input filter and protection circuit. - Main Power MOSFET (QMain) (12): Controlled by PWM signal It transmits energy to the transformer. - Clamp MOSFET (QClamp) (13): In the transformer when the switch is closed The accumulated energy is transferred to the clamp capacitor. ZVS (Zero Voltage Switching) 15 The conditions are met. - Transformer (T1) (14): Provides insulation between primary and secondary sides, voltage It carries out the transformation. A ferrite core is used in the design. Figure 2 shows the secondary side structure (2) of the converter that is the subject of the invention. The secondary party (2) includes the following: - Synchronous MOSFETs (QSync1 & QSync2)(21): Used instead of diodes, low It causes transmission loss. - Output LC Filter (22): Suppresses voltage ripple, with low ripple. It provides a clean DC output. 25 - Vout Terminal (23): Load supply is done from here. Figure 3 shows the view of the control unit (3) of the converter that is the subject of the invention. The control unit in question (3) includes the following: - PWM Controller (31): Specially developed for active clamp forward topology, duty 30 It incorporates control functions such as cycle control, slope compensation, and UVLO. - Feedback Input (32): Voltage generated by optocoupler and external circuitry Its power supply is connected to this pine. 8 Figure 4 shows the view of the gate drives (4) of the converter that is the subject of the invention. The gate drives (4) include the following: - Second-side Gate Drivers (41): Used for secondary MOSFETs. Fast, These are drives with high sink / source current. Figure 5 shows the ripple and noise full load view of the converter that is the subject of the invention. Figure 6 shows the transient response of the converter, which is the subject of the invention, with a 25% load step change. Its appearance is shown in Figure 7, one of the sample 20-watt pinouts of the converter that is the subject of the invention. The appearance and external dimensions of the converter, the subject of the invention, are shown in Figure 8. It takes. 10 For example, this configuration can be used for low output levels such as 5V / 4A, as well as 12V / 8.33A. This same active clamp forward structure is maintained for higher power applications as well. It can be adapted (Table 1). Table 1. Efficiency (20 W) Furthermore, the output voltage is designed to be adjustable by ±10%, so the same product It can be integrated into different subsystems. Thus, the product family consists of a single piece of hardware. Its infrastructure has enabled it to meet many system requirements.

Claims

1 REQUESTS 1. The invention relates to switched-mode power supplies and energy conversion systems; 9–36 V or a wide input voltage range of 18–72 V and / or low output such as 5V / 4A It can be used for various levels, as well as higher power levels such as 12V / 8.33A. adaptable to applications while maintaining the same active clamp forward structure; - Capable of operating within an input voltage range of 9–36 V or 18–72 V, with input filter and Win input supported by protection circuit (11), - PWM with active clamp forward topology, supplying power to the transformer. Main power MOSFET (QMain) (12) controlled by signal, - Configured to provide ZVS (Zero Voltage Switching), when the switch is closed, the energy stored in the transformer is transferred, Clamp mosfet (QClamp) (13), - transformer (T1) (14) which provides isolation between primary and secondary sides, primary party structure (1), - Synchronous diodes used instead of diodes to provide low transmission loss. MOSFETs (21), - Output LC that suppresses voltage ripple and provides a clean DC output. filter (22), - Vout terminal to which the load is supplied (23): secondary party structure (2), - optocoupler-based feedback system, UVLO, soft-start, and hiccup. PWM Controller (31) which includes protection functions together, - voltage feedback generated by optocoupler and external circuitry feedback input (32) is the pin to which it is connected. control unit (3), - external high sink / source current used for secondary MOSFETs. second-party gate drives with capacity (41), gate drives (4), - ensures stable operation without minimum load requirements. It has a control algorithm. - Power and thermal emission optimization for EMI suppression and thermal conductivity purposes. It has a 16-layer PCB architecture with separated ground planes, 2 - Scalable modular design for different output voltage and current configurations. product family infrastructure, It is characterized by a high-efficiency isolated DC-DC converter.

2. Characterized by transformer (T1) (14) containing ferrite core, in accordance with Claim 1. is being done.

3. Output LC filter (22) that provides a clean DC output with low ripple, in accordance with claim 1. It is characterized by...

4. Developed specifically for active clamp forward topology, in accordance with Claim 1, duty cycle, PWM includes control functions such as slope compensation and UVLO. It is characterized by its controller (31).

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